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Design & Analysis of Spring used in Dual Mass

Flywheel
Mr. Ankush Namdev Pawar Dr. A. D. Bagawade
Mechanical Engg. Department
SVPM College Of Engg. Malegoan (Bk) Mechanical Engg. Department
Baramti, Dist –Pune, India SVPM College Of Engg. Malegoan (Bk)
Baramti, Dist –Pune, India

Abstract— All engines have flywheels that balance out material has the required combination of rigidity and
compression and power strokes, maintain idle speed, aid elasticity: technically, a wooden bow is a form of spring. [13]
starting and reduce parts wear. Dual mass flywheel is a multi-
clutch device which is used to dampen vibration that occurs due Functions of Spring
to the slight twist in the crankshaft during the power stroke. Following are the objectives of a spring when used
When the operating speed of the engine is low, vibration occurs as a machine member:
due to the torsional resonance and this can be avoided using 1. Cushioning, absorbing, or controlling of energy
dual mass flywheel Spring. This work is carried out to study the due to shock and vibration. Car springs or railway buffers to
effect material changing of springs on the dual mass flywheel. control energy, springs-supports and vibration dampers.
The main aim is to increase the vibration absorbing capacity
and to increase durability of the spring and to elimination of
2. Control of motion maintaining contact between
gear rattle. First design steel, aluminum, copper and brass two elements (cam and its follower) in a cam and a follower
material springs as per our load. Then modeling in Creo 2.0 A arrangement, widely used in numerous applications, a spring
three dimensional model of a single spring are optimized by maintains contact between the two elements. It primarily
modal analysis and static structural deformation using controls the motion.
ANSYS13.00. Manufacture, Compare with Ansys 13.00 and FFT Creation of the necessary pressure in a friction
analyzer, Validation of result. device (a brake or a clutch) A person driving a car uses a
brake or a clutch for controlling the car motion. A spring
Keywords— Design springs for steel, aluminum, copper and system keep the brake in disengaged position until applied to
brass material, Modeling of springs in Creo 2.0 , Manufacture,
Compare with Ansys 13.00 and FFT analyzer, Validation of result.
stop the car. The clutch has also got a spring system (single
springs or multiple springs) which engages and disengages
INTRODUCTION the engine with the transmission system. Restoration of a
A spring is defined as an elastic body, whose machine part to its normal position when the applied force is
function is to distort when loaded and to recover its original withdrawn (a governor or valve) A typical example is a
shape when the load is removed. Spring act as a flexible joint governor for turbine speed control. A governor system uses a
in between two parts which provides cushioning effect for spring controlled valve to regulate flow of fluid through the
this system a spring is an elastic object used to store turbine, thereby controlling the turbine speed.
mechanical energy. Springs are usually made out of spring 3. Measuring forces
steel. There are a large number of spring designs; in everyday Spring balances, gauges like no. of equipment which
usage the term often refers to springs. Small springs can be used to measure the force which act on that body
wound from pre-hardened stock, while larger ones are made 4. Storing of energy
from annealed steel and hardened after fabrication. In clocks or starters The clock has spiral type of spring
Some non-ferrous metals are also used including phosphor which is wound to coil and then the stored energy helps
bronze and titanium for parts requiring corrosion resistance gradual recoil of the spring when in operation. Nowadays we
and beryllium for springs carrying electrical current (because do not find much use of the winding clocks. Before
of its low electrical resistance). considering the design aspects of springs we will have a
quick look at the spring materials and manufacturing
When a coil spring is compressed or stretched methods. [15]
slightly from rest, the force it exerts is approximately
proportional to its change in length (this approximation 1.1.2Terminology of Helical Coil Spring
breaks down for larger deflections). The rate or spring Helical springs.
constant of a spring is the change in the force it exerts, The helical springs are made up of a wire coiled in
divided by the change in deflection of the spring. it is the form of a helix and are primarily intended for
the gradient of the force versus deflection curve compressive or tensile loads. The cross-section of the wire
An extension or compression spring has units of force from which the spring is made may be circular, square or
divided by distance, for example N/m. The inverse of spring rectangular. Helical compression springs have applications to
rate is compliance, the stiffness (or rate) of springs in parallel resist applied compression forces or in the push mode, store
is additive, as is the compliance of springs in series. energy to provide the "push". Different forms of compression
Depending on the design and required operating environment, springs are produced.
any material can be used to construct a spring, so long as the

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The helical springs are said to be closely coiled rotational speeds as being one of the emerging energy storage
when the spring wire is coiled so close that the plane technologies available today in various stages of
containing each turn is nearly at right angles to the axis of the development, especially in advanced technological areas, that
helix and the wire is subjected to torsion. in other words, in a is spacecraft’s. Today, most of the research efforts are being
closely coiled helical spring, the helix angle is very small, it spent on improving energy storage capability of flywheels to
is usually less than 10 degree. The major stresses produced in deliver high power transfer, lasting longer than conventional
helical springs are shear stresses due to twisting. The load battery powered technologies. This study solely focuses on
applied is parallel to or along the axis of the spring. In open exploring the effects of dual mass flywheel geometry for
coiled helical springs, the spring wire is coiled in such a way improving energy storage capability to deliver high power
that there is a gap between the two consecutive turns, as a transfer per unit mass, as compared to conventional flywheel.
result of which the helix angle is large. Dual mass flywheel also reduces the weight of the flywheel
using composite materials. In this study using the two spring
Literature review two mass system to produce useful vibrations which will be
The recent development in the automotive sector is employed to increase the inertia of the system and thereby
diminishing due to the demand by the automotive industry for enable to reduce the weight of existing flywheel or increase
saving cost during the increase in the research and power output using existing weight of flywheel. They
development phase. When taking survey then following concluded that there is approximately 7 to 8 % increase in
revives obtained power output by using the Dual mass flywheel and also
Dr. K .Annamalai & A .Govinda (2014)studied the observed that the Dual mass flywheel is 5 to 6 % efficient
theoretical and experimental dynamic behavior of different than the conventional flywheel which will also result in
materials for dual mass flywheel spring Dual mass flywheel increasing fuel economy of the engine. [02].
is a multi-clutch device which is used to dampen vibration
Park, Dong hon Suwon- si ,Kyunggi do (2000)
that occurs due to the slight twist in the crankshaft during the
[6]invented about a dual mass flywheel for a vehicle includes
power stroke. The torsional frequency is defined as the rate at
us a primary flywheel connected to a crank shaft of an engine
which the torsional vibration occurs. When the torsional
a dumper housing integrally formed in a circumfertially
frequency of the crankshaft is equal to the transaxles torsional
direction of the primary flywheel .A secondary flywheel
frequency an effect known as the torsional resonance occurs.
connected to an input shaft of a transmission and rotating
When the operating speed of the engine is low, vibration
mounted on a hub of primary flywheel. Driven fingers
occurs due to the torsional resonance and this can be avoided
integrally formed the second flywheel and insert the
using dual mass flywheel. This work is carried out to study
vertically in to the dumper housing to be forced by the
the effect of arc springs on the dual mass flywheel. The main
dumper spring .The dumper springs compresses two spring
aim is to increase durability of the arc spring and to
sets symmetrically disposed within the dumper housing .one
elimination of gear rattle. A three dimensional model of a
end of each dumper springs being driven by the stoppers
single arc spring, hard-soft spring combination and single
which are integrally formed on primary flywheel. While the
mass with arc springs are optimized by modal analysis and
other end of springs drives the driven finger of the secondary
fatigue analysis using ANSYSThe torsional frequency is
fly wheel. The primary and secondary flywheels are
defined as the rate at which the torsional vibration occurs.
integrally provided which projections for preventing the
When the torsional frequency of the crankshaft is equal to the
dumper spring from excessively compressed & damaged. The
transaxles torsional frequency an effect known as the
dumper spring compressed a plurality of springs .Each having
torsional resonance occurs. The vibration caused by the
difference springs coefficients and the dumper springs are
torsional resonance when the operating speed of the engine is
supported by a plurality of a sliding guide or blocks in that
low can be avoided using dual mass flywheel. This work is
way torsional vibrations of cranck shaft get reduced with the
carried out to study the effect of arc springs on the dual mass
help of Dual Mass Flywheel [03].
flywheel, a three dimensional model of a single arc spring,
two arc springs with different stiffness and single mass with Ulf Shaper, Oliver Sawodny, Tobias Mahl and
arc springs are optimized using ANSYS. The simulation of UtiBlessing(2009) [5]those research about -The Dual Mass
fatigue analysis is also performed using ANSYS. [01] Flywheel (DMF) is primarily used for dampening of
D. G. Dighole, Prof. R.S. Shelke, Prof. Dr. S.N. oscillations in automotive power trains and to prevent
Shelke (2015)studied about the rapid developments of vehicle gearbox rattling. TWs paper explains the DMF mechanics
technology over the last few decades, flywheels have been along with its application and components. Afterwards
used to achieve smooth operation of machines. The early detailed abs-initio model of the DMF dynamics is presented.
models where purely mechanical consisting of only a stone This mainly includes a model for the two arc springs in the
wheel attached to an axle. Nowadays, flywheels are complex DMF and their friction behavior. Both centrifugal effects and
constructions where energy is stored mechanically and redirection forces act racially on the arc spring which induces
transferred to an integrated motor/generator. The stone wheel friction. A numerical simulation of the DMF model is
has been replaced by a steel or composite rotor and magnetic compared to measurements for model validation. Finally the
bearings have been introduced. Today flywheels are used as observe ability of the engine torque using the DMF is
supplementary UPS storage at several industries world over. discussed. For this purpose a linear torque observer is
Flywheels serve as kinetic energy storage and retrieval proposed and evaluated. In today's world power train control
devices with the ability to deliver high output power at high sits acclimates torque information to perform various tasks.

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These tasks include for example the clutch acnl3tion in to release the impact produced by the step changes of
automated manual transmissions and dual-clutch stiffness. This new DMF can avoid impact and noise more
transmissions as well as the control of electric motors in effectively. By adding a compensation device, a new DMF
hybrid power trains. Indirect torque estimation is needed with continuously variable stiffness is presented to release the
because the direct measurement of the transmuted torque impact produced by the step changes of stiffness. [06].
using strain gages cannot be done in volume production cars Sagar N Khurd, Prasad P Kulkarni, Samir D
for economic reasons. One source for power train torque Katekar(2015)study represents new approach to design
estimation is the engine itself. However, the torque estimation helical coil spring by using workbench. Response surface
provided by the internal combustion engine is based on modeling and analysis of helical spring by considering
complex thermodynamic models. These engine models tend Translational invariance have been carried out. In previous
not to be reliable in all situations .Critical a picture indeed the paper we had considered longitudinal invariance. Design
accuracy of the lobo charger models and the influence of parameters are wire diameter, coil diameter, height, number
exhaust gas recirculation on combustion calculation. [4]. of turns elastic modulus in X and Y direction, force. Simple
equation is proposed which gives value of compressive stress
Rudolf Glassner(2013) [6]studied about Dual Mass
of helical coil spring by carrying out regression analysis done
flywheel of driver train of vehicle includes a primary
by M S excels, It is observed that force and material property
flywheel mass, Secondary flywheel mass & coupling device.
are significant parameters which affect compressive stress
The coupling device include at least two pivot levers
because their P value is 1. Relationship among design
associated with secondary flywheel mass with inter act with a
parameters and compressive stress has been obtained. In this
control profile formed on primary flywheel mass. The pivot
analysis it is observed that coil diameter increases stress on
levers are pre tensional against control profile in a radial
the spring decreases. It is observed that force and material
direction by the elastic element. a control segment of elastic
property are significant parameters which affect compressive
element is disposed radially inside control profile. An object
stress. [07]
of the present invention is to provide a dual mass flywheel
C.Madan Mohan Reddy
having coupling device which has fewer speed dependent
,D.RavindraNaikDrM.LakshmiKantha Reddy (2014) studied
coupling characteristics .In the Dual mass flywheel in
about present work is carried out on modeling, analysis and
accordance with the invention the centrifugal force acting on
testing of suspension spring is to replace the existed steel
elastic elements in operation is minimized in that elastic
helical spring used in popular two wheeler vehicle. The stress
elements are more closely to axis of rotation of dual mass
and deflections of the helical spring is going to be reduced by
flywheel than previously usual If the flywheel is too light the
using the new material. The comparative study is carried out
motorcycle requires more effort to start, idles badly, and is
between existed spring and new material spring. Static
prone to stalling. Weight is not the important factor here, but
analysis determines the stress and deflections of the helical
inertia. Inertia is stored energy, and is not directly
compression spring in finite element analysis. The testing
proportional to flywheel weight. It’s possible to have a light
proto type is used to test the spring under different loading
flywheel with much more. Any power the motor develops
conditions. Finite element analysis methods (FEA) are the
must accelerate the flywheels before leaving the sprocket
methods of finding approximate solutions to a physical
shaft, and any used in bringing the flywheel up to speed is not
problem defined in a finite region or domain. FEA is a
available at the rear wheel [05].
mathematical tool for solving engineering problems. In this
Li Quan Song , Li Ping Zeng,Shu Ping Zhang ,Jian the finite element analysis values are compared to the
Dong Zhou Hong En Niu(2014) was develops new structure experimental values. A typical two wheeler suspension spring
of new structure of dual mass flywheel (DMF) with is chosen for study. The modeling of spring is developed on
continuously variable stiffness is proposed based on pro/E 5.0 analysis is carried out on ansys 14. They conclude
compensation principle in order to release the impact that the comparative study has been carried out in between
produced by the step changes of stiffness. By theoretical the theoretical values to the experimental values and the and
calculation and experiments, the proposed structure and the analytical values. The maximum shear stress of chrome
design theory involved are proved to be feasible for reducing vanadium steel spring has 13-17% less with compare to hard
the torsional vibration of the power transmission system for drawn steel spring. [08]
automobiles with large-power and high-torque engines. The
natural characteristics of the vehicle power transmission ` Prince Jerome Christopher J, Pavendhan R.(2010)
system carrying the DMF are analyzed to investigate the studied about vehicles problem happens while driving on
influence of torsional stiffness on the first-order and the bumping road condition. The objective of this project is to
second-order resonance speeds. The results show that this design and analyze the performance of Shock absorber by
new DMF can lower the idle speed of the engine, realize high varying the wire diameter of the coil spring. The Shock
counter torque at a large torsional angle, and avoid the impact absorber which is one of the Suspension systems is designed
due to the abrupt changes of stiffness. An inertia balance mechanically to handle shock impulse and dissipate kinetic
mechanism is proposed to eliminate the inertia forces energy. It reduces the amplitude of disturbances leading to
produced by moving parts of the compensation device, which increase in comfort and improved ride quality. The spring is
can successfully put the torque compensation theory into compressed quickly when the wheel strikes the bump. The
engineering practice. By adding a compensation device, compressed spring rebound to its normal dimension or
a new DMF with continuously variable stiffness is presented normal loaded length which causes the body to be lifted. The

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spring goes down below its normal height when the weight of and has been optimized for the selection of material, wire
the vehicle pushes the spring down. This, in turn, causes the diameter, carbon percentage and other governing parameters
spring to rebound again. The spring bouncing process occurs & concluded that as the diameter of spring increases,
over and over every less each time, until the up-and-down Ultimate Tensile Strength increases. As the carbon
movement finally stops. The vehicle handling becomes very percentage increases, the Ultimate Tensile Strength increases,
difficult and leads to uncomfortable ride when bouncing is but flexibility decreases. As the diameter increases, factor of
allowed uncontrolled. Hence, the designing of spring in a safety increases. As the carbon percentage increases, the
suspension system is very crucial. The analysis is done by factor of safety graph shifts up with respect to the previous
considering bike mass, loads, and no of persons seated on grades. As the carbon spring is oil hardened, the strength
bike. Comparison is done by varying the wire diameter of the increases and the factor of safety curve shifts up. [11]
coil spring to verify the best dimension for the spring in N. N. Suryawanshi1, Prof. D. P. Bhaskar (2015)
shock absorber. Modeling and Analysis is done using studied about Dual Mass Flywheel (DMF) is primarily used
Pro/ENGINEER and ANSYS respectively. They have for dampening of oscillations in automotive power trains and
designed a Shock Absorber used in 160 cc bike and we have to prevent gearbox rattling. We explained detailed initial
modeled it using 3D parametric software called Pro/Engineer. model of the DMF dynamics is presented. This mainly
The shock absorber design is modified by reducing the includes the two arc springs and two masses in the DMF and
diameter and stress analysis is performed. The stress value is their behavior. An experimental the DMF model is compared
lesser in our designed spring than in original which adds an to convention flywheel. Finally the observation of the engine
advantage to our design. By comparing the results in the table torque using the DMF is discussed. For this purpose the DMF
we could analyses that our modified spring has reduced in is manufactured and done experiment or testing to see the
weight and it is safe. [09] results. And then results are comparing with the conventional
Mehdi Bakhshesh, and MajidBakhshesh (2012) both flywheel &both concluded that there is approximately 10 %
studied about springs that can reserve high level of potential increase in power output by using the Dual mass flywheel.
energy, have undeniable role in industries. Helical spring is [12].
the most common element that has been used in car Saurabh Singh(2012) studied about demonstrates the
suspension system. In this research, steel helical spring feasibility of adopting composite material for design of
related to light vehicle suspension system under the effect of helical coil suspension system. In this paper the combination
a uniform loading has been studied and finite element of steel and composite material is used in place of
analysis has been compared with analytical solution. conventional steel only. The composite material used in this
Afterwards, steel spring has been replaced by three different analysis is Glass Fiber/Epoxy. The cause of implementing
composite helical springs including E-glass/Epoxy, combination of steel and composite material was because of
Carbon/Epoxy and Kevlar/Epoxy. Spring weight, maximum the low stiffness of single composite spring, which limits its
stress and deflection have been compared with steel helical application to light weight vehicle only. And conclude that
spring and factors of safety under the effect of applied loads that combination of conventional steel and composite
have been calculated. It has been shown that spring material can increase the stiffness; which is the major
optimization by material spring changing causes reduction of requirement however the ever demanding need of weight
spring weight and maximum stress considerably. In any case, reduction of vehicles will be satisfied by employing this
with changing fiber angle relative to spring axial, composite method. The weight reduction in this combination of material
spring properties have been investigated & concluded that a [13]
helical steel spring has been replaced by three different
composite helical springs. Numerical results have been Demin Chena, Yueyin Ma, Wei Sun, XiaolinGuo,
compared with theoretical results and found to be in good Xaofei Shi (2011) studied about In order to reduce torsion
agreement. Compared to steel spring, the composite helical vibration of automotive powertrain, angular stiffness formula
spring has been found to have lesser stress and has the most of arc helix spring was built according to the performance
value when fiber position has been considered to be in parameter of a C-grade car. Based on the expression, a
direction of loading. Weight of spring has been reduced and method of optimization design about arc helix spring is
has been shown that changing percentage of fiber, especially proposed with the variable radian. A new Dual Mass
at Carbon/Epoxy composite, does not affect spring weight. Flywheel (DMF) with 6 arc helix springs is designed. The
Longitudinal displacement in composite helical spring is torsion vibration simulation model of automotive power train
more than that of steel helical spring and has the least value is established by MSc. Easy and the system is analyzed.
when fiber position has been considered to be in direction of Further, the experiment is made and proves that the design of
loading. The most safety factor is related to case that fiber DMF can satisfy the use of the car & they concluded that
position has been considered to be perpendicular to loading angular stiffness formula of arch helix spring are calculated; a
and it is for Carbon/Epoxy composite helical spring. [10]. new design optimization method of DMF is proposed with
Pavan Kumar AV, Vinayaka N, Dr P B Shetty, radian as the main variables. The DMF of six arch helix
DrKiranAithal S, Gowtham V studied about that the Helical springs is designed. The torsion vibration model of a C-Class
Compression spring has been designed in such a way that car is built by Msc.Easy5, and the vibration reduction effect
when the vehicle travels over the spring, the spring takes the of DMF designed is simulated. Finally, the experiment on the
maximum load of 200 kg and the rest is taken by the ground. DMF is carried out and results show that it meets design
For this purpose, the spring is analyzed for the fatigue loads requirements. This method given in the paper can be used to

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select the appropriate arc helix springs for DMF to avoid [7] Sagar N Khurd, Prasad P Kulkarni, Samir D
resonance between the transmission and engine. It makes the Katekar,“Probabilistic design of helical coil spring for
DMF better match with the vehicle's transmission system and Translational invariance by using Finite Element Method”
access to the best effect of reducing vibration and noise. International Research Journal of Engineering and Technology
(IRJET) e-ISSN: 2395 -0056 Volume: 02 Issue: 06 | Sep-2015
Therefore, it is quite important to improve vehicle comfort, [8] C.Madan Mohan Reddy D.RavindraNaikDrM.LakshmiKantha
the transmission efficiency and prolong the transmission life. Reddy,” Analysis And Testing Of Two Wheeler Suspension
[14] Helical Compression Spring”,IOSR Journal of Engineering
By Alaster John Young (2000) [6]explained about a (IOSRJEN) www.iosrjen.org ISSN (e): 2250-3021, ISSN (p):
twin flywheel comprising first and second co axially arranged 2278-8719 Vol. 04, Issue 06 (June. 2014),
flywheel masses which are mounted for limited angular [9] Prince Jerome Christopher J, Pavendhan R.” Design and
rotation relative to the each other .The flywheel masses are Analysis of Two Wheeler Shock Absorber Coil Spring”,
inter connected at least one linkage arrangement comprising a International OPEN ACCESS Journal Of Modern Engineering
multi-link linkage having two or more circumfetially spaced Research (IJMER)11 may 2007.
[10] Mehdi Bakhshesh, and MajidBakhshesh,” Optimization of
main links pivotally mounted on second flywheel masses Steel Helical Spring by Composite Spring”,
with the circumfertially adjust pair of main links inter INTERNATIONAL JOURNAL OF MULTIDISCIPLINARY
connected by extending connected linkage and anchor link SCIENCES AND ENGINEERING, VOL. 3, NO. 6, JUNE
which connect to the multi linkage with first flywheel mass 2012
.Relative rotation of flywheel mass causes multi-link linkage [11] Pavan Kumar AV, Vinayaka N, Dr P B Shetty, DrKiranAithal
which connect to the second flywheel mass by anchor link , S, GowthamV,”Design and analysis of Helical compression
so that when twin mass is rotating ,relative rotation of spring”, International Journal of Emerging Technology and
flywheel masses resisted by centrifugal forces acting on Advanced Engineering Website: www.ijetae.com (ISSN 2250-
linkage . Any particular link may in the form of unitary link 2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 8,
August 2014)
in the form of parallel pair’s plates. Associated with one or [12] N. N. Suryawanshi, Prof. D. P. Bhaskar,” An Experimental
more links or pivots acting between flywheel masses there Study of Dual Mass Flywheel on Conventional Flywheel
may be controlling means to control the relative rotation of onTwo stroke petrol engine.”, International Journal of
flywheel masses[15]. Engineering Research and General Science Volume 3, Issue 2,
CONCLUSION Part 2, March-April, 2015
With respect to above all Paper work following [13] Saurabh Singh,” Optimization of Design of Helical Coil
conclusion are drawn: Suspension System by Combination ofConventional Steel and
 There is number of problems due to less deflection Composite Material”, International Journal of Applied
in previously used springs Which can be overcome Engineering Research, ISSN 0973-4562 Vol.7 No.11 (2012)
[14] Demin Chena, Yueyin Ma, Wei Sun, XiaolinGuo, Xaofei Shi,”
by used of newly used material spring by increasing Research of Design and Vibration Reduction of Dual Mass
deflection of spring Flywheel
with Arc Helix Spring”, International Conference on Electronic
 For our research we select Brass, Aluminum, & Mechanical Engineering and Information Technology,2011
Copper material springs for overcome above [15] Mr. Alastair John Young, Design Spring of twin mass
mention problem. flywheel, United State Patent,Patent No. 6029539, Date of
patent; Feb 29,2000
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